Rotary and Flat Screen Printing on Knit Fabrics
Screen printing remains the lowest-cost option for high volumes, provided screens, paste viscosity and drying are controlled properly.
The following sections cover the definition, the specification values, production control, testing and commercial impact.
Rotary versus flat screens
Rotary screens print continuously at high speed, while flat screens suit large repeats and delicate fabrics.
For most programmes the decision is taken during development, when changing the specification still costs nothing more than one sampling round.
Paste and viscosity control
Pigment or dye paste viscosity governs penetration and edge definition, so it is measured and adjusted between runs.
Review the limits each season against actual performance data instead of carrying the same figures forward indefinitely.
- Request test reports on production fabric, not on development samples
- Verify the sampling plan and the number of specimens
- Store reports with roll or lot identification for traceability
Curing and drying
Insufficient curing causes crocking; excessive heat distorts elastane blends and changes the hand feel.
Keep a physical standard at the machine so operators compare against the approved sample rather than memory.
Design limitations
Colour count, repeat size and registration tolerance all constrain what a screen-printed design can achieve.
Compare results before and after the intended care regime, since performance often changes after the first wash.
- Agree tolerances in writing before the first sample is made
- Define the measurement condition and the direction measured
- Review the limit each season against real performance data
Cost per colour
Each colour adds a screen and a printing station, so the break-even point against digital moves quickly.
Plan the calendar with the approval steps in mind, since late approvals delay production regardless of capacity.
Summary
The technical content is straightforward. The discipline lies in writing it down, testing it on production fabric and repeating the result on the next order.
